Remove/Install A/C Compressor

Tightening Torques

- Suction hose on pipe line:
with Cu seal 60 ± 5 Nm
without Cu seal 70 ± 5 Nm

- Pressure hose on pipe line:
with Cu seal 45 ± 5 Nm
without Cu seal 55 ± 5 Nm

- Pipe line to refrigerant compressor 17 Nm

- Oil check plug 15-17 Nm

- 8 mm screw 35 Nm

- 10 mm screws 30-45 Nm

- 12 mm screws 40-45 Nm

The refrigerant compressor can be removed and installed together with refrigerant compressor carrier only. If the compressor is removed because of leaks on compressor or on system, correct oil level in compressor by filling-up again, but fill-in only max. 200 cc refrigerant oil.

If the refrigerant compressor is renewed, drain all the refrigerant oil from new refrigerant compressor. Then add max. 200 cc oil. If the system is flushed with refrigerant R-11, fill 300 cc refrigerant oil into refrigerant compressor.

Attention! If the refrigerant compressor must be renewed, e.g. because of a blocking effect, the pipe line with hoses on refrigerant compressor should also be replaced on principle, since there is a possibility that small parts (abrasives) of refrigerant compressor may flow into pipe line, where removal by flushing with R-11 may not be possible up to 100 %.

When loosening or tightening hose or pipe connections, be sure to apply counterhold with a second open-end wrench.

Removal

1 Cover front fender.

2 Discharge air conditioning system. Procedures

3 Remove radiator. Service and Repair





4 Unscrew belt tensioning roller (12) on refrigerant compressor carrier (3) and remove V-belt (15).

5 Unscrew pressure and suction hose from pipe line (16).

6 Unscrew screw (20) on carrier for pressure oil pump.





7 Unscrew screw (17) and remove pipe line (16) from refrigerant compressor paying attention to sealing rings.

8 Screw pressure-testing plate to refrigerant compressor by means of available fastening members (17).





9 Unscrew screws (5) from supporting angle (4) or on oil pan upper half.





10 Unscrew two screws (11) on refrigerant compressor carrier (3) rear, as well as two screws (10) on engine face.

11 Pull electric plug connection from compressor.

12 Remove V-belt for power steering pump. Service and Repair

13 Remove refrigerant compressor in forward direction.

14 Unscrew refrigerant compressor from refrigerant compressor carrier (3) by unscrewing 4 screws (7 and 8).





15 If the pipe line (16) requires removal, turn pipe line by 180° and remove in downward position.

Layout refrigerant compressor (1st and 2nd version)

1 Refrigerant compressor 9 Spacing ring
3 Carrier
7 Inch screw with washer
8 Inch screw with washer
11 Inch screw
16 Pipe line
17 Inch screw with snap ring





Layout of refrigerant compressor with new pipe line on engine 116.98 and 117.98 and (USA) starting model year 1975 with engine 117 (4.5)

1 Refrigerant compressor
2 Electromagnetic clutch
3 Carrier
10 Hex socket screw
12 Belt tensioning roller
15 V-belt
16 Pipeline
19 Closing cap
20 Screw with washer, snap ring and hex screw

Installation

16 Correct oil level in refrigerant compressor.

17 Screw refrigerant compressor (1) to refrigerant compressor carrier (3) (with parts item 7 to 9) (item 7 and 8 are inch screws).

18 Install pipe line (16).





19 Install refrigerant compressor with refrigerant compressor carrier. Screw to cylinder crankcase and to supporting angle (4) or to oil pan upper half (with parts items 5, 10 and 11).





20 Under 3rd version (vehicles 107, 024/044) a disc (part no.169902440) must be added in-between engine and carrier of grey iron engines. On light-alloy engine (116 and 117) the carrier for the refrigerant compressor is mounted without a disc.





21 Remove pressure test plate, provide 0-rings on refrigerant compressor with refrigerant oil and renew, if required. Then screw pipe line (16) again to refrigerant compressor by means of screw (17).

22 Mount V-belt for power steering pump and tension. Service and Repair





23 Screw pipe line (16) (with parts item 20) to carrier for pressure oil pump or cylinder head.

16 Pipeline
20 Screw wiht washer (spacing washer on engine 116 (3.8 only)





24 Screw tensioning roller (12) to refrigerant compressor carrier (3). Mount V-belt (15) and tension.

Note: Check alignment of pulley - compressor in relation to pulley - crankshaft and tensioning roller and correct with compensating washers (14) between tensioning roller and refrigerant compressor carrier, if required.

25 Plug electric double plug to refrigerant compressor.

26 Install radiator.

27 Connect pressure and suction hose to pipe line (16).

28 Evacuate air conditioning system and fill up again.

29 Run engine and check cooling system for leaks.

30 Check air conditioning system for function.